Air Conditioning (Hatchback): Overview Volkswagen Beetle A4

A/C REFRIGERANT SYSTEM, IDENTIFICATION

Note. Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures SAFETY PRECAUTIONS .

A/C refrigerant systems on New Beetle models are charged with refrigerant R-134a.

A label specifying refrigerant type may be located on the compressor or radiator support.

HEATING AND A/C PASSENGER COMPARTMENT COMPONENT OVERVIEW

Note. Before carrying out any work on the A/C refrigerant system, refer to A/C refrigerant system safety measures SAFETY PRECAUTIONS . System components identified with an * must only be serviced or replaced after discharging refrigerant system. Use Kent Moore ACR4 or equivalent.

Scheme 31

1. Heating and A/C controls With A/C Evaporator Temperature Switch -E33- With Fresh Air Blower Switch -E9- With Fresh Air Blower/Recirculated Air Switch -E184- Removing and installing «HEATING AND A/C CONTROLS»(ref-492805-S01922093192012080600000) Assembly «HEATING AND A/C CONTROLS COMPONENT OVERVIEW»(ref-492805-S40906769742012080600000)
2. Dust and pollen filter Removing and installing «DUST AND POLLEN FILTER»(ref-492801-S12800298122012080600000)
3. Side window air outlet Removing «SIDE WINDOW AIR OUTLETS»(ref-492801-S03396938762012080600000)
4. Side air outlets Removing «SIDE AIR OUTLETS»(ref-492801-S33468912862012080600000)
5. Center air outlet console Removing «CENTER AIR OUTLET CONSOLE»(ref-492801-S38268480632012080600000)
6. Instrument panel cross member Loosening and tightening «INSTRUMENT PANEL CROSSMEMBER»(ref-492801-S14727030012012080600000)
7. Fresh/Recirculating Air Door Motor -V154- Removing and installing «FRESH/RECIRCULATING AIR DOOR MOTOR»(ref-492801-S11139268952012080600000)
8. Fresh Air Blower -V2- Removing and installing «FRESH AIR BLOWER»(ref-492801-S39230962432012080600000)
9. Fresh Air Blower Series Resistor With Fuse -N24- First remove Fresh Air Blower -V2- «FRESH AIR BLOWER»(ref-492801-S39230962432012080600000)
10. Intermediate duct
11. Cables Installing and adjusting «HEATING AND A/C CABLES COMPONENT OVERVIEW»(ref-492805-S21587893762012080600000)
12. Rear footwell duct
13. Gasket
14. Connecting duct With front footwell air outlet Removing «CONNECTING DUCT»(ref-492801-S07842865882012080600000)
15. Heater/evaporator unit* Disassembly and assembly «HEATER/EVAPORATOR UNIT»(ref-492805-S16538004702012080600000)
16. Heater core* Removing, heater/evaporator unit, disassembly and assembly, refer to «HEATER/EVAPORATOR UNIT»(ref-492805-S16538004702012080600000) Always use new coolant after replacement
17. Heater core/bulkhead seal Note installation position «HEATER CORE BULKHEAD SEAL, INSTALLATION POSITION»(ref-492801-S24222096562012080600000)
18. Defroster duct Replacing: Remove instrument panel «Removal and Installation»(ref-492755-S39811613742012080600000) Loosen instrument panel cross member «INSTRUMENT PANEL CROSSMEMBER»(ref-492801-S14727030012012080600000) .
19. Instrument panel Removing and installing «Removal and Installation»(ref-492755-S39811613742012080600000)
20. Center air outlet duct
21. Defroster air outlet panel Removing «SIDE WINDOW AIR OUTLETS»(ref-492801-S03396938762012080600000)

Scheme 32

1. Heating and A/C controls With A/C Evaporator Temperature Switch -E35- With Fresh Air Blower Switch -E9- With Fresh Air Blower/Recirculated Air Switch -E184- Removing and installing «HEATING AND A/C CONTROLS»(ref-492805-S01922093192012080600000)
2. Illumination filter
3. Trim panel
4. Fresh Air Control Illumination -L16- 12V, 1.2W
5. Rotary control For blower speed To remove: Use pliers with suitable plastic or rubber protection on jaws
6. Rotary control For air distribution To remove: Use pliers with suitable plastic or rubber protection on jaws
7. Rotary control For interior temperature To remove: Use pliers with suitable plastic or rubber protection on jaws

HEATING AND A/C CABLES COMPONENT OVERVIEW

Note. Cable sleeve ends are color coded. Check cables before installing. Replace binding or damaged cables. Attach cables to removed controls first and then attach to levers at heating/evaporator unit. All air doors must audibly move onto end stops when turning controls.

Scheme 33

1. Central door cable From air distribution rotary control to central door Cable sleeve marking: Yellow Installing and adjusting «CENTRAL DOOR CABLE»(ref-492805-S28123158092012080600000)
2. Footwell/defrost door cable From air distribution rotary control to footwell/defrost door Cable sleeve marking: Green Removing: -- Remove heating and A/C controls «HEATING AND A/C CONTROLS»(ref-492805-S01922093192012080600000) -- Unclip cable from controls -- Remove steering column trim. «Removal and Installation»(ref-492720-S22323760422012080600000) -- Unclip cable at heater/evaporator unit. Installing: -- Installing and adjusting «FOOTWELL/DEFROST DOOR CABLE»(ref-492805-S20446737002012080600000)
3. Heating and A/C controls Removing and installing «HEATING AND A/C CONTROLS»(ref-492805-S01922093192012080600000)
4. Temperature door cable From temperature rotary control to temperature door Cable sleeve marking: Beige Installing and adjusting «TEMPERATURE DOOR CABLE»(ref-492805-S19619656262012080600000)

HEATING AND A/C ENGINE COMPARTMENT COMPONENT OVERVIEW

Note. Before carrying out any work on the A/C refrigerant system, refer to A/C refrigerant system safety measures SAFETY PRECAUTIONS . System components identified with an * must only be serviced or replaced after discharging refrigerant system.

Scheme 34

1. Damper*
2. Refrigerant hose* With damper
3. Refrigerant pipe*
4. Ambient Temperature Switch -F38- Switches off A/C Clutch -N25- at low ambient temperatures Off at -1°C (30°F) On at 7°C (45°F)
5. Refrigerant pipe From receiver drier to expansion valve
6. Low pressure service valve Only use Kent Moore ACR4 or equivalent
7. A/C Pressure Switch -F129- or High Pressure Sensor -G65- Depending on engine type, refrigerant systems have either an A/C Pressure Switch -F129- or High Pressure Sensor -G65- installed. Refer to appropriate wiring diagram. A/C Pressure Switch -F129-, checking «A/C PRESSURE SWITCH, CHECKING»(ref-492805-S14434820522012080600000) High Pressure Sensor -G65-, checking «HIGH PRESSURE SENSOR, ELECTRICAL TESTING»(ref-492805-S22841534942012080600000) Removing and installing «A/C PRESSURE SWITCH AND HIGH PRESSURE SENSOR»(ref-492805-S31528662262012080600000) Component can be removed without discharging refrigerant system
8. Expansion valve*
9. Evaporator water drain valve from 06.00 Checking «EVAPORATOR WATER DRAIN VALVE FROM 06.00, CHECKING»(ref-492805-S04821365732012080600000) .
10. Evaporator water drain valve through 05.00 Checking «EVAPORATOR WATER DRAIN VALVE THROUGH 05.00, CHECKING»(ref-492805-S09072668052012080600000) .
11. A/C Cut-Out Thermal Switch -F163- Switches off A/C Clutch -N25- at excessively high coolant temperature Off at 119°C (246°F) On at 112°C (234°F)
12. Coolant Fan control (FC) control module -J293
13. Refrigerant hose* From compressor to condenser
14. Refrigerant hose From expansion valve to compressor With damper
15. Pressure relief valve* On compressor Checking «PRESSURE RELIEF VALVE, CHECKING»(ref-492805-S13799667482012080600000)
16. Condenser*
17. Compressor* Sanden SD7-V16
18. A/C Clutch -N25- Servicing «A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW»(ref-492805-S32559740912012080600000) .
19. Receiver drier*

Scheme 35

The compressor is driven via a belt on the engine when the A/C Clutch engages (A/C "ON").

Low-pressure refrigerant gas from the evaporator is compressed by the compressor. After compression, the refrigerant gas (now high-pressure) flows to the condenser.

Refrigerant system pressures and A/C outlet temperatures are regulated by cycling the A/C clutch on and off according to the selected temperature.

Note. The compressor contains refrigerant oil that is mixable under all temperatures with the refrigerant. A label on the compressor indicates that compressor is for R-134a systems only.

Scheme 36

The compressor is driven continuously via a belt on the engine.

Low-pressure refrigerant gas from the evaporator is compressed by the compressor. After compression, the refrigerant gas (now high-pressure) flows to the condenser.

Refrigerant system pressures and A/C outlet temperatures are regulated by external control of A/C Compressor Regulator Valve -N280-.

Scheme 37

The condenser transfers heat from the compressed refrigerant gas to the outside air which causes the refrigerant to change state from a gas to a liquid.

Note. The condenser for the R-134a refrigerant system is identified with a green label.

Scheme 38

The receiver drier acts as a refrigerant reservoir for the system. Any moisture in the system is absorbed in the drier desiccant.

A/C REFRIGERANT SYSTEM CONTROLS COMPONENT OVERVIEW

Note. Before carrying out any work on the A/C refrigerant system, refer to A/C refrigerant system safety measures SAFETY PRECAUTIONS . Except where indicated with all system components illustrated must only be serviced or replaced after discharging refrigerant system.

Scheme 39

1. Damper
2. Refrigerant hose
3. Refrigerant pipe
4. Refrigerant pipe From receiver drier to expansion valve
5. High pressure service valve Only use Kent Moore ACR4 or equivalent
6. A/C Pressure Switch -F129- (4-Pin) or High Pressure Sensor -G65- (3-Pin)* Depending on engine type, refrigerant systems have either an A/C Pressure Switch -F129- or High Pressure Sensor -G65- installed. Refer to appropriate wiring diagram. A/C Pressure Switch -F129-, checking «A/C PRESSURE SWITCH, CHECKING»(ref-492805-S14434820522012080600000) High Pressure Sensor -G65-, function «HIGH PRESSURE SENSOR, FUNCTION»(ref-492805-S25293862482012080600000) , multi-pin connector assignments «HIGH PRESSURE SENSOR, MULTI-PIN CONNECTOR ASSIGNMENTS»(ref-492805-S16698414622012080600000) , electrical checks «HIGH PRESSURE SENSOR, ELECTRICAL TESTING»(ref-492805-S22841534942012080600000) . Removing and installing «A/C PRESSURE SWITCH AND HIGH PRESSURE SENSOR»(ref-492805-S31528662262012080600000) Component can be removed without discharging refrigerant system
7. Expansion valve
8. Evaporator In heater/evaporator unit Removing, heater/evaporator unit, assembly, refer to «HEATER/EVAPORATOR UNIT»(ref-492805-S16538004702012080600000)
9. Refrigerant hose
10. Refrigerant hose From compressor to condenser
11. Condenser Removing and installing «CONDENSER»(ref-492805-S05613664802012080600000)
12. Pressure relief valve On compressor Checking «PRESSURE RELIEF VALVE, CHECKING»(ref-492805-S13799667482012080600000)
13. Compressor
14. A/C Clutch -N25- Clutch assembly can be serviced without discharging refrigerant system. Servicing «A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW»(ref-492805-S32559740912012080600000) .
15. Receiver drier

A/C REFRIGERANT SYSTEM COMPONENT OVERVIEW

Note. Before carrying out any work on the A/C refrigerant system, refer to A/C refrigerant system safety measures SAFETY PRECAUTIONS . Except where indicated with * all system components illustrated must only be serviced or replaced after discharging refrigerant system.

Note. During servicing, all couplings, fittings and related fasteners must be torqued to specifications.

Scheme 40

1. Sealing plug 15 Nm
2. O-ring 10.8 mm; 1.8 mm
3. Receiver drier
4. O-ring 10.8 mm; 1.8 mm
5. Refrigerant pipe From receiver drier to expansion valve
6. Bolt 15 Nm
7. A/C Pressure Switch -F129- (4-Pin) or High Pressure Sensor -G65- (3-Pin) Depending on engine type, refrigerant systems have either an A/C Pressure Switch -F129- or High Pressure Sensor -G65- installed. Refer to appropriate wiring diagram. A/C Pressure Switch -F129-, checking «A/C PRESSURE SWITCH, CHECKING»(ref-492805-S14434820522012080600000) High Pressure Sensor -G65-, function «HIGH PRESSURE SENSOR, FUNCTION»(ref-492805-S25293862482012080600000) , multi-pin connector assignments «HIGH PRESSURE SENSOR, MULTI-PIN CONNECTOR ASSIGNMENTS»(ref-492805-S16698414622012080600000) , electrical checks «HIGH PRESSURE SENSOR, ELECTRICAL TESTING»(ref-492805-S22841534942012080600000) . Removing and installing «A/C PRESSURE SWITCH AND HIGH PRESSURE SENSOR»(ref-492805-S31528662262012080600000) Component can be removed without discharging refrigerant system
8. O-ring 10.8 mm; 1.8 mm
9. Refrigerant pipe
10. Threaded plate
11. O-ring 10.8 mm; 1.8 mm
12. Expansion valve
13. Bolt 8 Nm
14. O-ring 14 mm; 1.8 mm
15. High pressure service valve Only use Kent Moore ACR4 or equivalent
16. Refrigerant pipe
17. Low pressure service valve Only use Kent Moore ACR4 or equivalent
18. O-ring 7, 6 mm; 1.8 mm
19. Evaporator In heater/evaporator unit Removing, heater/evaporator unit, disassembly and assembly, refer to «HEATER/EVAPORATOR UNIT»(ref-492805-S16538004702012080600000)
20. O-ring 16.7 mm; 1.8 mm
21. Insulation
22. O-ring 7, 6 mm; 1, 8 mm
23. Bolt 8 Nm
24. Refrigerant hose From compressor to condenser
25. Bolt 15 Nm
26. O-ring 10.8 mm; 1.8 mm
27. Condenser Removing and installing «CONDENSER»(ref-492805-S05613664802012080600000)
28. Compressor Sanden SD7-V16 Removing and installing compressor bracket «DESCRIPTION AND OPERATION»(ref-492805-S08178147852012080600000)
29. O-ring 14.3 mm; 2.4 mm
30. Bolt 20 Nm
31. O-ring 10.8 mm; 1.8 mm
32. A/C Clutch -N25- Sanden Servicing «A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW»(ref-492805-S32559740912012080600000) .
33. Refrigerant hose
34. O-ring 10.8 mm; 1.8 mm
35. Damper

Scheme 41

A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) or equivalent VAG 1331

Note. The compressor bracket and related components can be removed and installed without having to open the refrigerant circuit. If it is necessary to open the refrigerant circuit, for example when replacing compressor, first extract A/C refrigerant using recycling/recovery unit Kent-Moore ACR4 A/C REFRIGERANT SYSTEM, DISCHARGING . Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures SAFETY PRECAUTIONS Ribbed belt, routing Ribbed Belt Routing . Observe length of removed bolts and reinstall accordingly.

Scheme 42

1. Bracket Mounting for: Generator Compressor Power steering pump Diesel Direct Fuel Injection (DFI) Pump Removing without opening refrigerant circuit: -- Remove ribbed belt Removal and Installation -- Remove Generator (GEN) «Removal and Installation»(ref-492701-S33013738602012080600000) -- Remove power steering pump «Removal and Installation»(ref-492756-S27087900932012080600000) -- Remove Diesel Direct Fuel Injection (DFI) pump Removal and Installation -- Remove bolt -7- -- Remove compressor from bracket, swing away and secure in engine compartment with wire «A/C COMPRESSOR, SECURING TO BODY»(ref-492805-S00097665772012080600000) . -- Remove bolts -4- and -5- -- Remove compressor bracket from engine. Installing: -- Install in reverse order of removal, noting the following: -- Loosely install and then and torque bolts to specified value. -- Ribbed belt routing «Ribbed Belt Routing»(ref-492805-S30461475692012080600000)
2. Diesel Direct Fuel Injection (DFI) injection pump Removing: Removal and Installation
3. Power steering pump Removing: «Removal and Installation»(ref-492756-S27087900932012080600000)
4. Hex head combination bolt M10 X 65 45 Nm
5. Hex head combination bolt M10 X 45 45 Nm
6. Compressor Sanden SD7-V16 With A/C Clutch -N25- A/C Clutch -N25-, servicing «A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW»(ref-492805-S32559740912012080600000)
7. Hex head combination bolt Qty. 2 M10 X 112 45 Nm
8. Idler pulley Assembly «Idler Pulley»(ref-492805-S38679250032012080600000)
9. Generator (GEN) Removing: «Removal and Installation»(ref-492701-S33013738602012080600000)
10. Ribbed belt Removing: Removal and Installation Routing «Ribbed Belt Routing»(ref-492805-S30461475692012080600000)

Scheme 43

1 - Cover cap

2 - 25 Nm

3 - Relay roller

Scheme 44

Note. When installing the belt ensure it is correctly seated in the pulley.

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) or equivalent VAG 1331

Note. The compressor bracket and related components can be removed and installed without having to open the refrigerant circuit. If it is necessary to open the refrigerant circuit, for example when replacing compressor, first extract A/C refrigerant using recycling/recovery unit Kent-Moore ACR4 A/C REFRIGERANT SYSTEM, DISCHARGING . Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures SAFETY PRECAUTIONS Ribbed belt, routing Ribbed Belt, Routing . Observe length of removed bolts and reinstall accordingly.

Scheme 45

1. Ribbed belt Ribbed belt, routing «Ribbed Belt, Routing»(ref-492805-S14517915002012080600000) .
2. Hex head bolts M8 X 45 25 Nm Qty.: 3
3. Ribbed belt tensioner
4. Ribbed belt pulley with harmonic balancer
5. Hex head bolts M10 X 112 45 Nm Qty.: 2
6. Hex head bolts M8 X 85 Qty.: 2
7. Generator (GEN) Removing: «Removal and Installation»(ref-492701-S33013738602012080600000)
8. Compressor Sanden SD7-V16 With A/C Clutch -N25- A/C Clutch -N25-, servicing «A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW»(ref-492805-S32559740912012080600000)
9. Bracket Mounting for: Generator Compressor Power steering pump Removing without opening refrigerant circuit: -- Remove ribbed belt Removal and Installation -- Remove Generator (GEN) «Removal and Installation»(ref-492701-S33013738602012080600000) -- Remove power steering pump «Removal and Installation»(ref-492756-S27087900932012080600000) -- Remove bolts -5- -- Remove compressor -8- from bracket, swing away and secure in engine compartment with wire «A/C COMPRESSOR, SECURING TO BODY»(ref-492805-S00097665772012080600000) . -- Remove bolts -10- (Qty.: 6) -- Remove compressor bracket from engine. Installing: -- Install in reverse order of removal, noting the following: -- Loosely install and then and torque bolts torque bolts -10- in sequence to specified value, beginning with bolt -A-, then -B-, -C- and so on as illustrated. -- Ribbed belt routing «Ribbed Belt, Routing»(ref-492805-S14517915002012080600000)
10. Hex head bolts M10 X 45 45 Nm Qty.: 6 NOTE: When installing bracket, torque bolts in sequence beginning with bolt -A-, then -B-, -C- and so on as illustrated.
11. Hex head bolts M8 X 40
12. Hex head bolts M8 X 40
13. Power steering pump Removing: «Removal and Installation»(ref-492756-S27087900932012080600000)
14. Ribbed belt pulley
15. Hex head bolts M8 X 14 25 Nm Qty.: 3
16. Hex bolts M8 X 37 10 Nm plus a quarter turn (90 degrees) Qty.: 4

Scheme 46

Note. When installing the belt ensure it is correctly seated in the pulley.

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) or equivalent VAG 1331

Note. The compressor bracket and related components can be removed and installed without having to open the refrigerant circuit. If it is necessary to open the refrigerant circuit, for example when replacing compressor, first extract A/C refrigerant using recycling/recovery unit Kent-Moore ACR4 A/C REFRIGERANT SYSTEM, DISCHARGING . Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures SAFETY PRECAUTIONS Ribbed belt, routing A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW . Observe length of removed bolts and reinstall accordingly.

Scheme 47

1. Bracket Mounting for: Generator Compressor Power steering pump Removing without opening refrigerant circuit: -- Remove ribbed belt Removal and Installation -- Remove Generator (GEN) «Removal and Installation»(ref-492701-S33013738602012080600000) -- Remove power steering pump «Removal and Installation»(ref-492756-S27087900932012080600000) -- Remove bolts -8- -- Remove compressor -7- from bracket, swing away and secure in engine compartment with wire «A/C COMPRESSOR, SECURING TO BODY»(ref-492805-S00097665772012080600000) . -- Remove bolt -3- where applicable. -- Remove bolts -4- (Qty.: 5) and -5-. -- Remove compressor bracket from engine. NOTE: Bracket comes in two versions «Bracket Versions»(ref-492805-S13247730072012080600000) . Installing: -- Install in reverse order of removal, noting the following: -- Loosely install all bolts. -- Torque bolts in sequence ton specified value «Bracket Mounting, Installation Sequence»(ref-492805-S29862626032012080600000) -- Ribbed belt routing «Ribbed Belt, Routing»(ref-492805-S34736577142012080600000)
2. Intake manifold bracket Where applicable
3. Hex socket bolt Where applicable M10 X 70 45 Nm Observe installation sequence «Bracket Mounting, Installation Sequence»(ref-492805-S29862626032012080600000) .
4. Hex socket bolt M10 X 45 45 Nm Observe installation sequence «Bracket Mounting, Installation Sequence»(ref-492805-S29862626032012080600000) .
5. Hex socket bolt Only with bracket version -A- where applicable «Bracket Versions»(ref-492805-S13247730072012080600000) . M10 X 45 45 Nm Observe installation sequence «Bracket Mounting, Installation Sequence»(ref-492805-S29862626032012080600000) .
6. Bushing Only with bracket version -A- where applicable «Bracket Versions»(ref-492805-S13247730072012080600000) .
7. Compressor Sanden SD7-V16 With A/C Clutch -N25- A/C Clutch -N25-, servicing «A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW»(ref-492805-S32559740912012080600000)
8. Hex head bolt M10 X 112 45 Nm

Scheme 48

When installing bracket, proceed as follows

Locate bracket on engine block.

First install bolts -1- and -2- hand tight (allows slight repositioning of bracket for other bolts if necessary)

Then install remaining bolts -3-, -4-, -5- and -6- in order as illustrated.

Torque all bolts to 45 Nm.

Scheme 49

A - Bracket with bushing -arrow- uses six mounting bolts.

B - Bracket without bushing uses five mounting bolts.

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) or equivalent VAG 1331

Note. The compressor bracket and related components can be removed and installed without having to open the refrigerant circuit. If it is necessary to open the refrigerant circuit, for example when replacing compressor, first extract A/C refrigerant using recycling/recovery unit Kent-Moore ACR4 A/C REFRIGERANT SYSTEM, DISCHARGING . Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures SAFETY PRECAUTIONS Observe length of removed bolts and reinstall accordingly.

Scheme 50

1. Ribbed belt tensioner
2. Generator (GEN) Removing: «Removal and Installation»(ref-492701-S33013738602012080600000)
3. Bracket Mounting for: Generator Compressor Power steering pump Removing without opening refrigerant circuit: -- Remove ribbed belt Removal and Installation -- Remove Generator (GEN) «Removal and Installation»(ref-492701-S33013738602012080600000) . -- Remove power steering pump «Removal and Installation»(ref-492756-S27087900932012080600000) -- Remove bolts -7-. -- Remove compressor from bracket, swing away and secure in engine compartment with wire «A/C COMPRESSOR, SECURING TO BODY»(ref-492805-S00097665772012080600000) . -- Remove bolts -4- (Qty. 4). -- Remove compressor bracket from engine. Installing: -- Install in reverse order of removal, noting the following: -- Loosely install and then and torque bolts to specified value.
4. Hex socket bolt Qty. 4 M10 X 55 50 Nm
5. Power steering pump Removing: «Removal and Installation»(ref-492756-S27087900932012080600000)
6. Compressor Sanden SD7-V16 With A/C Clutch -N25- A/C Clutch -N25-, servicing «A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW»(ref-492805-S32559740912012080600000)
7. Hex head bolt M10 X 112 45 Nm

Special tools and workshop equipment required

1. Torque wrench 5-50Nm VAG 1331 (or 5 - 50 Nm equivalent)

Note. The compressor bracket and related components can be removed and installed without having to open the refrigerant circuit. If it is necessary to open the refrigerant circuit, for example when replacing compressor, first extract A/C refrigerant using recycling/recovery unit Kent-Moore ACR4 A/C REFRIGERANT SYSTEM, DISCHARGING . Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures SAFETY PRECAUTIONS Ribbed belt, routing A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW Observe length of removed bolts and reinstall accordingly.

Scheme 51

1. Bracket Mounting for Generator Compressor Power steering pump Coolant pump Removing without opening refrigerant circuit: -- Remove ribbed belt «Removal and Installation»(ref-492813-S40668215842012080600000) . -- Remove Generator (GEN) «Removal and Installation»(ref-492701-S33013738602012080600000) -- Remove power steering pump «Removal and Installation»(ref-492756-S27087900932012080600000) -- Remove bolts -7-. -- Remove A/C compressor from bracket and secure to body with appropriate material (e.g. welding wire) «A/C COMPRESSOR, SECURING TO BODY»(ref-492805-S00097665772012080600000) -- Remove bolts -2- through -4- and remove bracket -1- from engine. Installing: -- Install in reverse order of removal, noting the following: -- Loosely install and then and torque bolts to specified value. -- Route ribbed belt according to diagram «Ribbed Belt, Routing»(ref-492805-S08358811252012080600000)
2. Socket head bolt M8x60 25 Nm
3. Socket head bolt M8x110 25 Nm
4. Hex socket bolt M8x30 25 Nm Qty. 4
5. Dowel sleeves Qty. 2 Ensure proper seating between bracket and A/C compressor
6. A/C compressor With A/C Clutch -N25- A/C Clutch -N25-, servicing «A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW»(ref-492805-S32559740912012080600000)
7. Hex bolts M8x85 25 Nm Qty. 3
8. Tensioning roller
9. Hex bolt for engine support 40 Nm + 90 degrees Always replace Qty. 2
10. Engine support
11. Dowel sleeves Qty. 2

Scheme 52

1. Upper idler pulley
2. Ribbed belt pulley - generator
3. Lower idler pulley
4. Ribbed belt for generator and coolant pump
5. Ribbed belt pulley - A/C compressor
6. Ribbed belt for A/C compressor
7. Ribbed belt pulley - crankshaft
8. Tensioning roller for ribbed belt for A/C compressor
9. Tensioning roller for ribbed belt for generator and coolant pump
10. Ribbed belt pulley - coolant pump

A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW

Note. Refrigerant circuit does not need to be discharged to service A/C Clutch. If A/C Clutch is to be serviced with compressor installed, first do the following: Remove ribbed belt RIBBED BELT (1.8L, 2.0L, 2.5L), or [For engine(s) APH, BNU, AWP, AWV, BKF] RIBBED BELT or refer to [For engine(s) BPR, BPS] RIBBED BELT (1.9L TDI), or [For engine(s) BEW] Removal and Installation (1.9L TDI-PD) Remove intercooler (engine code ALH only). Refer to [For engine(s) ALH] Removal and Installation If A/C Clutch is to be serviced with compressor removed, first do the following: Discharge refrigerant system A/C REFRIGERANT SYSTEM, DISCHARGING . A/C Clutch, removing and installing A/C CLUTCH . A/C refrigerant system, servicing A/C REFRIGERANT SYSTEM .

Scheme 53

1. Hex nut Self-locking Always replace 15 Nm
2. Clutch plate Removing and Installing «A/C CLUTCH»(ref-492805-S34967836962012080600000) Checking clutch plate gap «Clutch Plate Gap»(ref-492805-S14038450792012080600000)
3. Shims Used to adjust gap between clutch plate and pulley Gap: 0.4 - 0.8 mm (0.015 - 0.023 in)
4. Circlip Always replace Install correctly: Flat side faces compressor. Ensure correct seating in groove
5. Clutch pulley Removing and Installing «A/C CLUTCH»(ref-492805-S34967836962012080600000)
6. Circlip Replacing Install correctly: Flat side faces compressor Ensure correct seating in groove
7. Clutch coil Installing «A/C CLUTCH»(ref-492805-S34967836962012080600000) NOTE: A thermo-fuse integrated into the clutch coil protects the A/C Clutch in the event of overheating (e.g.: due to a binding compressor). The clutch coil circuit is interrupted.
8. Connector clip With screw
9. Harness clip
10. Harness clip
11. Screw
12. Compressor
13. Threaded bushing

REFRIGERANT OIL R134A, IDENTIFICATION

Use only the correct type of refrigerant oil (PAG oil) specified for use with R-134a and compressor type.

Scheme 54

1. Function: Protects refrigerant circuit from excessive pressure.
2. The pressure relief valve plug indicates if valve has opened to release pressure -arrow-. An adhesive plate is pushed out.